Concrete wall structure



May 9, 1939. E` E. eclrm/IELLERA A 2,157,211

CONCRETE WALL STRUCTURE Filed July 25, 1937 4 Sheets-Sheet l (Ittomeg May 9, 1939- E. E. SCHMELLER 2,157,271

CONCRETE WALL STRUCTURE Filed July 25, 1957 4 sheets-sheet 2 Inventor (lttorneg emit asume/k May 9, 1939- v E. E. scHMx-:LLER- 2,157,271

CONCRETE WALL STRUCTURE /a ill- @m/www" nvento'r v/s a.

(Ittorneg v May 9, 1939- Ev E. SCHMELLER 2,157,271

CONCRETE WALL STRUCTURE Filed July 23, 1937 4 sheets-sheet 4 I llas-z? 1E y D( Emi/dbnelkr Zhweptor (Ittorneg 55 opening therein.`

Patented May 9, 1939 UNITED STATES PATENT oFFicE 2 Claims.

My present invention relates to an improved concrete Wall structure of the metal-reinforced, monolithic, and hollow type Which is adapted for use in small building structures, as garages 6 and other one-room and one-story building where the Walls of the building are each composed of a single concrete slab and the adjoining ends of the slabs or wa1l-sections are bonded together by concrete.` The invention is also capable of em- 10 bodiment in horizontally alined wall-sections bonded together and vertically alined wall-sections that are bonded together to form a complete wall of one, two, or more stories high according to the height of the building, and the usual window and door openings are provided where required.

In carrying out my invention I preferably fashion the wall section by superimposing successive concrete slabs within a horizontally disposed mold-box, and after the plastic material has set the integral wall section is turned onedge to upright position for erection either as a monolithic wall, or a number of sections are alined and bonded together to form the building wall,

and these building walls, usually at the corners,

are bonded together byconcrete'.

In the utilization of my invention I am enabled to manufacture a comparatively light but strong and durable wall section at low cost for labor and material, and the completed wall sections may readily be in building walls that are properly sustained and supported to insure permanence. 'I'he wall sections of my invention may be provided with interior heat-insulating cores, or the interior cellular structures of the Walls or wallsections may be left in hollow condition as desired. t

'Ihe invention consists in certain novel combinations and arrangements of parts as will here- 40 inafter be more fully set forth and claimed. In the accompanying drawings I have illustrated one complete example of the physical embodiment of my invention wherein the parts are combined and arranged according to one mode I have thus far devised for the practical application of the principles of my invention.

Figure 1 is a view in side elevation of a monolithic wall-section constructed accordingl to my invention, showing a window opening, and partly broken away for convenience of illustration.

Figure 2 is a top edge View of the Wall section of Figure 1.

Figure 3 is a horizontal sectional view of the wall-section. of Figure l, showing the window (Cl. 'l2-44) Figure 9 is a viewsimilar to Figure 8, but showing a solid, upright pilaster as the bond between adjoining edges of two wall-sections.

Figure 10 is a horizontal sectional View at a corner of a building structure, showing the formation of a corner bond between adjoining angularly disposed wall-sections.

\ Figure 11 is a vertical sectional view through a portion of the horizontally disposed mold or mold-box in which a wall-section has been cast. showing three superimposed slabs forming the integral wall-section, and showing also sandcores in the interior of the section.

Figure 12 is a detail sectional view of part of the mold or mold box with the plastic material omitted.

Figure 13 is a vertical sectional View through part of a horizontal ceiling or roof structure, showing the manner of supporting the horizontal section on ceiling or roof jois-ts which are supported on the top edges of the upright wallsections.

In Figure 1 a wall section is indicated as a whole by the numeral l, and this section, with its Window opening W may form an entire side wall of a rectangular building structure, or other similar wall-sections may be added at the sides and top of the illustrated section to form a larger Wall in which the sections are properly bonded together.

This hollow, upright wall-section is fashioned with spaced outer walls 2 and 3 and an intermediate or interior partition 4 and as shown these walls and the partition provide spaced cells which may be left vacant, or, during the process of casting these cells may be filled with a sand core as indicated at S in Figure 11 and the core thereafter used as an interior filler, or this filler may be made up of heat-insulating material as an element in the section.

The whole wall-secton is' bounded by a transversely extending wall 5, as is also the window opening W, and the bottom edge and the two side edges of section I are fashioned with extensions of these outer transverse walls that form outer spaced flanges 6 and 1 and an intermediate flange 8 that are alined with the face-walls 2 and and the interiorzpartition l.

As best seen in Figures 1 and 2 the top edge of the section I is fashioned with a single longitudinally extending edge-flange 9 that is alined with the flanges 6 of the section, and the plane top wall 5 which is depressed below the top edge of the flange 9 is fashioned with angular recesses or notches I0, shown as three in number to receive the ends of the ceiling or roof joists.

The interior structure of the section is reinforced by the use of Wires II that are crossed to form the usual mesh, and in addition I ernploy cast metal tie bars I2 extending transversely of the section and fashioned with retaining heads I3 embedded in the face walls and the interior partition. As indicated in Figure 1 the ends of the wires Il forming the reinforcing mesh are extended beyond the edges of the wall-section for use in making the bond between adjoining sections when the section is incorporated in a building structure.

In Figure 6, where the wall-section is shown supported on a concrete foundation I4 and its footing I5, the latter is fashioned with longitudinally extending, spaced tongues I6 that form` grooves to accommodate the flanges 6, 1, and the partition-flange 8 of the wall-section, and this joint is cemented together in suitable manner to form a seal, after the wall-section has been erected and placed in its true position on the footing orvfoundation.

In a one-room, one-story building structure, as for instance a garage, where the monolithic wallsection forms an entire side of the building, the angular upright Walls I and la in Figure 10 are joined by a corner bond I1 which is properly reinforced and cast of plastic concrete, and it will be seen that the two sets of three flanges of adjoining wall-sections provide grooves for the reception of tongues I8 that interlock with the flanges of the wall-sections. These bonds, which may be rounded at the corners as indicated may be cast in suitable molds erected at the corners of the building structure, and the bonded joint forms a fixed and permanent connection between the adjoining angular walls of' the building.

At opposite sides of the building are erected two upright wall-sections I, I with the recesses or mortises I0, I0, I in their top edges, and these mortises or notches are adapted to receive the ends of cast concrete inverted T-joists or rafters' IS in Figure 13, that support the roof structure. After the rafters or joists have been placed in proper position and the side walls of the building structure are rigidly joined together at the corners, the roof, or ceiling as the case may be, is cast in place with three thicknesses or slabs as shown in Figure 13 with an inner slab 20, an insulating layer 2 I, and the roof covering or outer slab 22. 'I'hese slabs are built or cast upon the usual wire mesh that is supported on the shoulders of the inverted T-joists or supporters I9, and they are fashioned in suitable and usual manner to complete the permanent weather-tight roof structure, for a single story building, as well as to form the ceiling and floor structure in a two (or more) story building.

For a finishing surface to the ceiling, horizontally disposed metalv laths or strips 23 are supported between the' joists, and a wire-mesh 24 attached thereto is employed to bond the finishing coat of plaster, or the coats of plaster that may be applied in usual manner.

. When a number of the wall-sections I and Ib in Figures 7, 8 and 9y are incorporated in a building wallthey are spaced apart a predetermined distance and their adjoining flanged edges are bonded together by cast concrete slabs 25, 26, and 21 in Figure 8 or a single solid pilaster 28 is used as in Figure 9.

In the form of Figure 8 the bonding slabs form spaced cells complementary to the cells of the adjoining wall-sections and these slabs 25, 26, 21, that are cast in the molds or mold boxes 29 erected as in Figure 7 between the adjoining flanges of the wall-sections, form continuations of the inner and outer face-walls and of the intermediate partition of the wall-sections. The projecting ends Il of the wire mesh are knotted as indicated and they are embedded within the spaced bonding slabs between the wall-sections. The mold-boxes 28 of course are removed after the bonding slabs have set.

The protruding wire ends I I are also embedded in the solid pilaster-bond 28 in Figure 9, and this solid bond is fashioned with spaced tongues 30, extending the full height of the pilaster, that are formed in the grooves between the flanges of the wall-sections, to insure a permanent bond or joint between the wall-sections.

In Figures 11 and 12 I have indicated a portion of a horizontally disposed mold box in which the wall-sections are cast on the j ob, and the wall-sections are afterward erected to their upright positions. The mold box is made up of super-imposed, rectangular sections including the base 3| resting on thefloor F, the two intermediate sections 32 and 33, and the top section 34. The two intermediate sections are provided with Wall-tongues 35 extending around three sides of the rectangular box and spaced apart above the bottom of the mold and below the top of the mold to provide for the three edge-flanges of the wall section I, and another side Aof the mold box is provided at the inner side of its wall with forms that fashion the mortises I0, the plane top and the top tongue 9 of the wall sections.

The adjoining faces of the superimposed moldbox-sections are grooved at 36 and the crossed reinforcing wires Il are laid in the successive sets of grooves to form the wire-mesh in each slab of the wall-section.

As a core for use in casting the successive slabs of the wall section I may use sand, as at S in Figure l1, and if desired this core may remain within the completed wall-section as a permanent filling. If the Wall-section is to be hollow, as in Figure 3 for instance, this sand core may 'be blown out through holes provided for the purpose in the face-slabs or face-walls of the wall section, in well known manner. In some instances a heat-insulating material may be substituted for the sand-core as a permanent feature of the wall-section.

Having thus fully described my invention, what I claim as new and desire to secure by Letters Patent is'.

1. A hollow monolithic wall-section comprising parallel spaced face Walls and an intermediate partition, transverse edge-walls having spaced flanges forming extensions of the face-walls and partition, the top edge-wall having a single flange forming an extension of one of the face-Walls, and said top edge wall having a number of open frontrnortises closed at the rear by said last mentioned face wall for the support of joists or rafters.'

2. A hollow monolithic wall-section comprising two spaced face walls and an intermediate partition, transverse edge-,Walls having spacedflanges forming extensions of the face-walls and partition, a. reinforcing wire-mesh embedded in said face-Walls and partition and having ends projecting through the flanges, the top edge-Wall having a single ange forming an extension of one of the face walls, and said top edge wall having a number of open-'front mortises closedl at their rear ends by said last mentioned face wall and located below said single flange.

EMIL E. SCHMELLER. 

